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Can a new matching return duct be installed without totally redoing everything that's already been done. In other words will they be able to place temporary supports under the AH, install the new return duct base, and lower the AH onto it, or will it have to be totally broken down?

If I request that they make a new bottom duct the same size as the air handler is this request considered reasonable?

Aside from the conduit on the outside, does the install violate in codes?

Most cities in my part of Texas have adopted it, some with thier own additional requirements. It is not reqired everywhere, as some places use different codes or don't have any, but should be followed as a minimum requirement in any case.

Both the line voltage wiring AND the low voltage control wiring should be in conduit where they are exposed outside.

The way they installed that air handler is poor. Basicly the only support it has is on a strip of metal on the front and the 1" flange in back. It is providing no support on the sides.
Due to the weight and odd size of the Trane varriable speed air handler, they should have used a Trane Perfect Fit media air filter under it and had a return stand sized to properly support the unit.

Just some thoughts on your situation.
Although the looks are not that great the return will work fine the way it is. I would have used a filter that fit the airhandler or made a transition from the filter to the bottom of the air handler. The opening in the bottom of the unit is about the same size as the filter but it looks sloppy the way they did it. I did see that you agreed to installing it this way so I don't know how they will react to wanting it changed now.

Things that show up in the pictures as a sloppy install are easy to pick out but the things we can't see are the ones that will cause you the biggest problems. There are to many things in these pictures that would suggest they were in a hurry, don't know better, or just don't care.

Originally posted by BoltonNC Did these guys seem in a hurry to get done?

Difficult to say. I've been working with this HVAC contractor for about two weeks. I've spent most of the time researching the web, getting advice from you guys, and getting prices on various pieces of equipment. The owner has been very accommodating and helpful so far. Hopefully he'll be as accomodating when I bring all of this to his attention.

By the way, worse case scenario. Suppose he refuses to accomodate me without additional charge. Am I within my rights to reject the job and have him remove all of the installed equipment, or am I legally responsible at this point?

Originally posted by trane I did see that you agreed to installing it this way so I don't know how they will react to wanting it changed now.

I agree, this is difficult. However I did question the install and based on their professional opinion I allowed them to proceed. Bad decision, but if they are a reputable company (which I believe they are) they should be willing to accomodate me.